US10025299B2 - System and method for self-contained modular manufacturing device having nested controllers - Google Patents

System and method for self-contained modular manufacturing device having nested controllers Download PDF

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Publication number
US10025299B2
US10025299B2 US14/876,564 US201514876564A US10025299B2 US 10025299 B2 US10025299 B2 US 10025299B2 US 201514876564 A US201514876564 A US 201514876564A US 10025299 B2 US10025299 B2 US 10025299B2
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Prior art keywords
self
manufacturing device
contained modular
modular
manufacturing
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US20170097633A1 (en
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Chace Howard Fadlovich
Robert Allen Brown
David James Whalen-Robinson
Michael Gary Woogerd
Eric J. Davis
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Airbus Robotics LLC
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MTM Robotics LLC
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Priority to US14/876,564 priority Critical patent/US10025299B2/en
Assigned to MOBILE TOOL MANAGEMENT, INC. reassignment MOBILE TOOL MANAGEMENT, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BROWN, ROBERT ALLEN, DAVIS, ERIC J., FADLOVICH, CHACE HOWARD, WHALEN-ROBINSON, DAVID JAMES, WOOGERD, MICHAEL GARY
Priority to EP16854075.5A priority patent/EP3359342B1/de
Priority to PCT/US2016/053096 priority patent/WO2017062187A1/en
Priority to PT168540755T priority patent/PT3359342T/pt
Priority to ES16854075T priority patent/ES2969438T3/es
Publication of US20170097633A1 publication Critical patent/US20170097633A1/en
Assigned to MTM ROBOTICS LLC reassignment MTM ROBOTICS LLC CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: MOBILE TOOL MANAGEMENT, INC
Assigned to MTM ROBOTICS LLC reassignment MTM ROBOTICS LLC CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: MOBILE TOOL MANAGEMENT, INC.
Priority to US16/010,309 priority patent/US10429824B2/en
Publication of US10025299B2 publication Critical patent/US10025299B2/en
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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • G05B19/41845—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by system universality, reconfigurability, modularity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J15/00—Riveting
    • B21J15/10—Riveting machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1602—Programme controls characterised by the control system, structure, architecture
    • B25J9/161—Hardware, e.g. neural networks, fuzzy logic, interfaces, processor
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/414—Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller
    • G05B19/4148—Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller characterised by using several processors for different functions, distributed (real-time) systems
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/34—Director, elements to supervisory
    • G05B2219/34205—Modular construction, plug-in module, lsi module
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/35—Nc in input of data, input till input file format
    • G05B2219/35029—Design of modular control system
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/40—Robotics, robotics mapping to robotics vision
    • G05B2219/40252—Robot on track, rail moves only back and forth
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/40—Robotics, robotics mapping to robotics vision
    • G05B2219/40296—Second arm can be attached to first arm, modular
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/40—Robotics, robotics mapping to robotics vision
    • G05B2219/40304—Modular structure
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/45—Nc applications
    • G05B2219/45088—Riveting robot
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/50—Machine tool, machine tool null till machine tool work handling
    • G05B2219/50158—Modular structure
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

  • FIG. 1 shows an isometric view of a set of modular tools forming a self-contained modular manufacturing device having a local processor for executing processing instructions independent of an overall manufacturing control system according to an embodiment of the subject matter disclosed herein.
  • FIG. 2 shows an exploded diagram of the isometric view of FIG. 1 showing the set of modular tools that form the self-contained modular manufacturing device of FIG. 1 according to an embodiment of the subject matter disclosed herein.
  • FIG. 3 shows an isometric view of an overall control system set in a manufacturing environment that includes the self-contained modular manufacturing device of FIG. 1 according to an embodiment of the subject matter disclosed herein.
  • FIG. 4 shows a block diagram of an overall control system set in a manufacturing environment that includes the self-contained modular manufacturing device of FIG. 1 according to an embodiment of the subject matter disclosed herein.
  • FIG. 5 shows a block diagram of an overall control system set in a manufacturing environment that includes the several self-contained modular manufacturing device of FIG. 1 according to an embodiment of the subject matter disclosed herein.
  • FIG. 6 shows a flow diagram of a method for using self-contained modular manufacturing device with nested controllers in the systems of FIGS. 4 and 5 according to an embodiment of the subject matter disclosed herein.
  • the subject matter disclosed herein is directed to a system (and method for use thereof) of a self-contained modular manufacturing device having modular tools and parts configured to collectively accomplish a specific task or function.
  • the modular device includes a housing that has a mount configured to engage a robotic arm or other form of maneuvering actuator (such a crane or gantry).
  • the housing may provide a base by which additional modules may be mounted and coupled.
  • the modular device also includes one or more interfaces configured to communicate with a remote control system capable of controlling the robotic arm.
  • the modular device also includes one or more other modules that are configured to accomplish a particular task or function. Such modules are sometimes called end-effectors and work in conjunction with each other to accomplish tasks and functions.
  • a processor disposed in the housing may be configured to control the functional tools (e.g., each end-effector) independent of the overall manufacturing control system.
  • the self-contained modular manufacturing device may be configured to calibrate itself with respect to other attached modules or with respect to an underlying manufactured item.
  • the modular device may include additional processors that are each capable of independent control of one more end-effectors such that the additional controllers are nested within the primary local controller within the self-contained modular manufacturing device.
  • a conventional robotic manufacturing system may include arm and actuators to which are attached end-effectors and other tooling.
  • the robot arm may move the end effector into position where the end effector performs the actual machining or assembly of the parts.
  • a human operator loads the two pieces of metal into the tooling, and, after the operator retreats to a safe distance from the robot, the operator pushes a button, or otherwise indicates to the robot that the robot can begin the fastening process.
  • the end-effector drills one or more holes through the two pieces of metal, inserts fasteners (e.g., rivets) into the holes, and installs the fasteners.
  • the robot may move the end-effector from hole position to hole position, or the robot may be installed on a device (e.g., a rail) that moves the robot from hole position to hole position.
  • the tooling may move the two pieces of metal relative to the end effector, or may be installed on a device (e.g., a rail or Automatic Guided Vehicle (AGV)) that moves the tooling.
  • AGV Automatic Guided Vehicle
  • the pieces e.g., pieces of an airplane wing
  • they may be moved and loaded into the tooling with machinery (e.g., heavy equipment), or the robot may be moved to the location of the pieces instead of the pieces being moved to the location of the robot.
  • machinery e.g., heavy equipment
  • the robot and the end effector in a conventional system, are controlled by a master control system and often through a central Programmable Logic Controller (PLC).
  • PLC Programmable Logic Controller
  • the PLC executes a software program to directly control all of the operations of the robot and the end effector, and to store information regarding the robot and end effector.
  • the PLC may access and execute a drill-hole software subroutine or object (or the PLC may be a state machine) that causes the PLC to generate one or more electrical analog or digital signals that are coupled to the end effector.
  • These signals e.g., drill on/off, drill speed, drill extend/retract
  • cause the drill motor to rotate the drill bit at a desired speed and to drill a hole.
  • the PLC may receive feedback signals (e.g., drill depth, drill speed) from feedback sensors so that the PLC can operate the items (e.g., drill) of the end effector in open loop or closed loop.
  • the PLC may also receive monitoring signals (e.g., temperature) from sensors so as to take corrective action if there is a problem (e.g., overheating, short circuit).
  • the software program (or state machine) that the PLC executes may be long, complex, unwieldy, and difficult and time consuming to update. For example, suppose a small change or update needs to be made to the drilling subroutine. A programmer may need to access, modify, recompile, debug, and reinstall the entire program just for this small change. And the debug may include testing the program on the entire manufacturing system, not just on the end effector, so that either the entire manufacturing system is down during this software update, or a separate robotic system or robot-system emulator needs to be purchased and maintained just for software updates.
  • the connector e.g., “umbilical cord” between the PLC and the end effector may be large and complex, and, due to the number of individual connections, may be unreliable. For example, such a connector may have from tens to hundreds of individual connection pins and receptacles.
  • the PLC needs to calibrate the end effector, swapping out an end effector is anything but trivial.
  • the PLC may calibrate open-loop offsets (e.g., previously calculated and stored drill-position offset, camera-position offset) based on a look-up table (LUT) that is unique to the end effector.
  • LUT look-up table
  • the PLC may match a serial number of the end effector with the proper LUT to make sure that the PLC is using the correct calibration offsets for that particular end effector. Therefore, when swapping out an end effector, the maintenance person may need to load the calibration data for the end effector into an LUT of the PLC. Even if it is relatively easy to load the calibration data into an LUT, this still presents an opportunity for error that may go undiscovered until one or more parts are machined or assembled out of specification.
  • end effector is designed as an integral unit
  • repairing the end effector may entail removing and shipping the entire end effector back to the equipment supplier even to diagnose a failure in, and to change, a relatively small part.
  • this means that the manufacturing system that is using the robotic control system may need to keep one or more spare end effectors on hand to swap out a broken end effector.
  • end effectors are relatively expensive, this adds significant cost to the manufacturer that uses the robot system under a master control system.
  • the tester must have an entire robot system, or at least a robot-system emulator. This adds expense, and may require a large space because the robot is typically large.
  • inventive self-contained modular manufacturing device address these disadvantages by providing a system and method of handling control aspects and calibration aspects of the end-effector using a modular device having a dedicated processor for controlling the actions of the end-effector in a self-contained manner.
  • problems associated with bulky and remote master control system are eliminated.
  • the modularity of the various portions of the overall manufacturing system is increased thereby reducing downtime and repair costs.
  • FIG. 1 shows an isometric view of a set of modular tools forming a self-contained modular manufacturing device 100 having at least one local processor for executing processing instructions independent of an overall manufacturing control system according to an embodiment of the subject matter disclosed herein.
  • the modular device 100 may include several modules 105 - 109 that are designed to interface with one or more other modules 105 - 109 within the modular device 100 .
  • the set of modules 106 - 109 function as one device 100 within the larger context of a manufacturing control system.
  • each module 105 - 109 may include its own dedicated processor (not shown in FIG. 1 ) for controlling aspects of the functions of each individual module.
  • the modular device 100 may include its own local controller with several nested controllers embedded within dependent modules.
  • each module 105 - 109 may be controlled by a single local processor embedded within one of the modules 105 - 109 .
  • a first local processor for controlling the aspects of one of the five modules (e.g., module 107 ) along with one or more additional nested controllers embedded with remaining modules 105 , 106 , 108 , and 109 is discussed.
  • the five modules 105 - 109 of the modular device 100 include an x-y-axis motion-actuator assembly 105 (hidden from view in FIG. 1 —see FIG. 2 for greater detail), a motor-spindle assembly 106 , an end-effector assembly 107 (as shown in FIG.
  • these five modules 105 - 109 may be controlled by one or more self-contained processors (not shown in FIG. 1 ) embedded in one or more of the five modules.
  • Each self-contained processor may include programming with executable routines and sub-routines for controlling each of the modules 105 - 109 .
  • a first sub-routine may be programmed for maneuvering the modular device along an x-axis rail (by controlling the x-y-axis motion-actuator assembly 105 ) and along a y-axis rail (by controlling the x-y-axis motion-actuator assembly 105 ) and the y-axis carriage assembly 108 .
  • a second subroutine may be programmed for selecting and delivering a specific fastener using the fastener-delivery assembly 109 .
  • a third subroutine may be programmed to control the motor-spindle assembly 106 to apply the appropriate drive force to the end-effector assembly 107 .
  • a fourth subroutine may be programmed to control the end-effector assembly 107 to apply the appropriate torque to the fastener that has been selected. Additional subroutine may also assist with the overall control of the self-contained modular manufacturing device 100 .
  • Each of these routines and subroutines may be executed by one or more of the processors embedded within each module 105 - 109 .
  • the self-contained modular manufacturing device 100 may also communicate with a master control system (shown in FIG. 3 ) as well. In this sense, the self-contained modular manufacturing device 100 may hand off control to a master control system until appropriate times and then be handed local control at the self-contained modular manufacturing device 100 so that the specific functionality of the device 100 can be accomplished, Such a back and forth nature is often called a control handshake wherein a master control system need not be aware of what the self-contained modular manufacturing device 100 is doing—rather the master control system need only be aware that the self-contained modular manufacturing device 100 is doing its thing.
  • a master control system shown in FIG. 3
  • Such communication may be realized through an umbilical cord 110 having a communication link, such as RS-232 or standard Ethernet. Further, the umbilical cord 110 may also have cabling for power to the various modules 105 - 109 of the self-contained modular manufacturing device 100 .
  • communication between the self-contained modular manufacturing device 100 and a master control system may be realized through wireless communications using common wireless communication protocols such as IEEE 802.11 and the like. Further, such a wireless embodiment may also include self-contained battery power such that any need for an umbilical cord 110 is eliminated. Additional details about each module 105 - 109 in the self-contained modular manufacturing device 100 are presented next with respect to FIG. 2 .
  • FIG. 2 shows an exploded diagram of the isometric view of FIG. 1 showing the set of modular tools that form the self-contained modular manufacturing device 100 of FIG. 1 according to an embodiment of the subject matter disclosed herein.
  • This exploded view also shows each of the five modules 105 - 109 from the example embodiment discussed above.
  • these modules include an x-y-axis motion-actuator assembly 105 , a motor-spindle assembly 106 , an end-effector assembly 107 , a y-axis carriage assembly 108 , and a fastener-delivery assembly 109 .
  • these five modules 105 - 109 may be controlled by one or more self-contained local controllers 200 - 204 embedded in a respective one of the modules 105 - 109 .
  • the local controller 200 may be a processor programmed to include routines and subroutines (which may be stored in a local memory not shown in FIG. 2 ) for controlling the end-effector module 107
  • the local controller 201 may be a processor programmed to include routines and subroutines for controlling the x-y axis actuator module 105 , and so on.
  • One or more of these local controllers 200 - 204 nay be programmed to control more than one module 105 - 109 .
  • the modular device 100 may include an x-y-z drive system that may include one or more drive assemblies for actuating an end effector to an x-direction, a y-direction and a z-direction.
  • the modular device 100 may include an x-y-axis motion-actuator assembly 105 , (for example, a screw-type drive assembly) that translates the end-effector 107 relative to a mount (such as a robot arm) in an x-direction and in a y-direction.
  • the modular device 100 may include a y-axis carriage assembly 108 , (again for example, a screw-type drive assembly) that carries the end-effector 107 relative to the mount in the y-direction.
  • the modular device 100 may include a z-axis motion-actuator assembly (not shown in FIG. 2 ) that translates the end-effector 107 relative to the mount in a z-direction.
  • one or more drive assemblies may translate the end-effector 107 in only one or two dimensions.
  • sensors coupled to one or more local controller 200 - 204 may provide feedback signals to the local controllers 200 - 204 so that the local controllers 200 - 204 can control various items via a closed loop control path.
  • a sensor may sense the x position of the x-y-z drive assembly such that the local controller 201 can stop movement of the drive in the x direction when the x-y-axis actuator assembly 105 attains the desired x-position.
  • the drive assemblies may be controlled by the local controller 201 to position the end-effector 107 in a position to accomplish its underlying function; in this case, the underlying function is to fasten one piece of metal to another piece of metal using a selected fastener.
  • the local controller 200 may execute another sub-routine for positioning the end-effector 107 at a precise location with respect to the first and second pieces of metal.
  • the various drive assemblies that are part of the modular device 100 may be used for granular positioning while one of the local controllers 200 - 204 may be in communication with a robotic arm to which the modular device 100 is mounted in order to control broader movement.
  • the local controller 201 may send signals to a robotic arm to move the modular device 100 to a general location, but then use the drive assemblies such as modules 105 and 108 ) within the modular device 100 to move the end effector to a precise location.
  • the end-effector 107 may further include a tool selection assembly such as a turret module 210 that is configured to position different tools or end-effectors that may be attached to the turret module 210 into a working position or other position.
  • the tool selection assembly may be a linear selection device.
  • the tool selection assembly may be a combination of different tool selection devices.
  • Examples of end-effectors that can be attached to the turret module 210 include a drill assembly, a camera assembly (to image, e.g., a drilled hole for analysis), a hole-depth determiner, a counter-sink-depth determiner, a fastener inserter, and a fastener installer.
  • the turret module 210 may include a motor that rotates the turret to position a selected one of the tools in a work or other position, such as positioning the drill to drill a hole.
  • the modular device 100 of FIG. 2 includes a fastener-delivery assembly 109 that may include a fastener-orientation mechanism that can properly orient and load fasteners for use at the end-effector 107 .
  • the fastener-load mechanism may receive from the local-controller 200 information identifying the size of the fastener to be delivered, or the mechanism may effectively be able to determine the size without input from the local controller 204 .
  • the tools on the turret module 210 may themselves be modular and self-contained with a dedicated local and nested controller. For example, one may be able to replace the drill, which includes a spindle motor assembly 106 and local motor controller (not shown), independently of the other tools in the overall modular device 100 .
  • the modular device 100 of FIG. 2 includes a human-machine interface 215 configured to provide a graphic user interface for local programmatic control of the device independent of the master control system.
  • the end-effector assembly 107 includes a local controller 200 that, e.g., handles communications to/from the master control system and that controls one or more next-level sub-controllers 201 - 204 (e.g., nested controllers) within the modular device 100 .
  • the local controller 200 may execute software that translates commands from the master control system into control signals or commands to sub-controllers 201 - 204 in the end effector, assembly 107 or other assemblies in the modular device 100 and that translates commands from the various sub-controllers 201 - 204 to the master control system.
  • Such simple commands from the local controller 200 may simply be to begin the modular device function such that control is relinquished to the local controller 200 for accomplishing said function. Then, after said function is complete, the local controller 200 may communicate to the master control system that said function is complete and that control is relinquished back to the master control system.
  • the master control system which is often a PLC, may have programming instructions that can be shortened and simplified as various commands to and from a coupled modular device 100 need only be minimal. Further, such PLC instructions at the master control system level need to be modified (or tested, debugged, and reinstalled) at all when software/firmware on board the modular device 100 is modified.
  • the PLC of the master control system can send commands to the modular device 100 instead of analog or digital signals.
  • an Ethernet connection e.g., CAT 6
  • the connector is smaller, less complex, and more reliable.
  • the modular device 100 may run from 110 VAC instead of a specialized supply voltage like 408 VDC.
  • the modular device 100 may store its own calibration data and may calibrate itself independently of the PLC of the master control system. This relieves the PLC memory of the burden of storing a calibration LUT for each possible modular device 100 in the system, and also eliminates the need to update such various LUTs when a modular device 100 is switched out. That is, swapping out an end-effector assembly 107 is now transparent to the PLC of the master control system because it requires no updates to the PLC software or stored calibration/configuration data.
  • the modular device 100 is designed as a modular unit, repairing the end-effector assembly 107 or other assembly in the modular device 100 entails shipping only the defective module back to the equipment supplier. This means that to avoid down time, the entity using the modular device system may need to keep only spare modules, not entire spare robots on hand to swap out with a broken or defective assembly or module. Furthermore, tests (e.g., a test after repair or after a software update) can be performed on the end-effector assembly 107 independently of the remainder of the robot system. Therefore, the tester need not have an entire master robot system or a robot-system emulator.
  • FIG. 3 shows an isometric view of an overall robotic control system 300 set in a manufacturing environment that includes the self-contained modular manufacturing device 100 of FIG. 1 according to an embodiment of the subject matter disclosed herein.
  • the system 300 includes a master control system 301 that may be a PLC or other programmable processor that is configured to control various robotic and automated subsystems within the overall robotic control system 300 .
  • a master control system 301 may be a PLC or other programmable processor that is configured to control various robotic and automated subsystems within the overall robotic control system 300 .
  • only one subsystem 302 is shown for simplicity, but a skilled artisan understands that the system 300 may include multiple subsystems.
  • the subsystem 302 shown in FIG. 3 shows a robotic stanchion 320 that has a robotic arm 310 mounted in a movable manner to the robotic stanchion 320 .
  • the robotic arm may be maneuvered in several directions and degrees of freedom to place a mounted modular manufacturing device 100 into a position near an underlying manufactured item, such as the ribbed structure 330 shown in FIG. 3 .
  • the self-contained modular manufacturing device 100 may take control of the robotic arm 310 if control is relinquished by the master control system 301 .
  • Such a control handshake is described above and not repeated in detail here.
  • FIG. 4 shows a block diagram of the system 300 of FIG. 3 set in a manufacturing environment that includes the self-contained modular manufacturing device 100 of FIG. 1 according to an embodiment of the subject matter disclosed herein.
  • the self-contained modular manufacturing device 100 includes the local controllers 200 - 204 described above for controlling actions and functions of various modules 105 - 109 the self-contained modular manufacturing device 100 and, at times, the robotic arm 310 .
  • each module 105 - 109 is shown with a respective local controller 200 - 204 , each of which may be configured to have similar components as are described next with respect to the controller 200 .
  • the local controller 200 includes a processor 407 configured to execute instructions that may be stored in a local memory 408 .
  • the memory 408 is coupled to the processor via a communication and data bus 406 .
  • the bus 406 is also coupled to one or more interfaces 405 for one or more end-effectors.
  • the interface 405 may be for coupling additional modular devices or other devices in a nested controller manner, such as modules 105 , 106 , 108 and 109 .
  • a first “top-level” controller 200 may be communicatively coupled to a second tier controller 201 within the x-y-axis actuator module 105 .
  • another tier of controllers 202 , 203 , and 204 may be nested and communicatively coupled to the controller 201 of the x-y-axis actuator module 105 .
  • control of functionality of various components within the overall modular device 100 may be passed back and forth between tiers of nested controllers 200 - 204 .
  • the modular device controller 200 also includes an input/output interface 410 suitable for handling communication signals to and from other related manufacturing devices and controllers in the system 300 .
  • the I/O interface 410 is communicatively coupled to a communication interface 420 housed within the robotic arm 310 .
  • the communication interface 420 may be within a stanchion 320 of the robotic arm as shown in FIG. 3 or may be in direct communication with the master control system 301 .
  • the communication protocol for these devices may be standard Ethernet using TCP/IP protocol.
  • Other embodiments may be a proprietary communication protocol, such as a proprietary “Smart Tool Protocol” (STP), using TCP/IP Ethernet or other standard serial or parallel interfaces (e.g., RS-232 or the like).
  • STP Smart Tool Protocol
  • the communication interface 420 associated with the robotic arm may be coupled to one or more robotic actuators configured to move the robotic arm 310 in one or more direction or orientations (such as pivoting or rotating).
  • the master control system 301 may include a master controller 460 that includes an I/O interface 461 , a processor 462 and a memory 463 for accomplishing master control tasks and functions.
  • FIG. 5 shows a block diagram of an overall control system 500 set in a manufacturing environment that includes the several self-contained modular manufacturing device 100 of FIG. 1 according to an embodiment of the subject matter disclosed herein.
  • the system 500 includes the modular device 100 having a local controller 200 . This may be similar to the modular device 100 described in FIGS. 1-4 . Additionally, the system 500 includes three more modular devices 510 , 520 and 530 that each respectively include local controllers 511 , 521 , and 531 . These modular devices may be arranged in a hierarchy of control such that one or more of the controllers 200 , 511 , 521 , and 531 may exert control over one or more of the individual modular devices 100 , 510 , 520 , and 530 .
  • modular devices 100 and 510 may be coupled to a network 501 .
  • the network is further coupled to a master control system 301 having a master controller 460 . Further the network may be coupled to a robotic arm actuator system 310 .
  • modular device 520 and 530 are coupled to the modular device 510 . In this respect, communications are routed through the modular device 510 and not directly through the network 510 .
  • Several other alternative arrangements and hierarchies may exists but are not shown further for brevity.
  • FIG. 3 Various methods may be realized using the system 300 of FIG. 3 which is exemplified in the block diagrams of FIG. 4 and FIG. 5 ; an embodiment of one method is described next with respect to FIG. 6 .
  • FIG. 6 shows a flow diagram of a method for using one or more self-contained modular manufacturing devices with nested controllers in the systems of FIGS. 4 and 5 according to an embodiment of the subject matter disclosed herein.
  • the method described with respect to the flow diagram of FIG. 6 is for an underlying manufacturing function for drilling and fastening together two pieces of metal that are being held by tooling.
  • the order and number of steps, and the steps themselves, may be different in other embodiments.
  • the method begins at step 600 and proceeds to a first step 601 wherein the master controller 460 may be engaged for maneuvering a first self-contained modular manufacturing device 100 to a position to accomplish a first manufacturing function.
  • the master controller 460 may first move a modular device having a drilling assembly as an end effector 107 such that a hole may be drilled by the end-effector 107 of the first modular device 100 .
  • the master controller 460 may then indicate, at step 603 , to the first modular device 100 that the first modular device is at (or close to) the drill position.
  • the actual control of the modular device may be passed to the modular device 100 such that a local controller 200 may now engage the accomplishing of the drilling function.
  • the accomplishing of the first manufacturing function is undertaken via the first local controller 200 disposed in the first modular device 100 .
  • the local controller 200 of the first modular device 100 may then control other modular devices to accomplish additional functions prior to passing control back to the master controller 460 .
  • the first controller 200 may maneuver a second device 510 into the function position at step 609 and then indicate to the second device 510 at step 613 that it is now in position for its function.
  • a second function may be accomplished by the second modular device 510 under control of a second local controller 511 as control is then passed to the second controller 511 at step 615 .
  • control is passed to the second controller 511 , the second modular device 510 can then engage, through its local controller 511 , to accomplish the second manufacturing function at step 617 .
  • the second modular device controller 511 may indicate to the first local controller 200 that the second function has been accomplished at step 619 .
  • control may be passed from the second controller 511 to the first controller 200 .
  • overall control may be passed back to the master controller 460 .
  • Additional optional or alternative steps in this method include storing results of accomplishing the manufacturing functions in a local memory disposed in the one or more of the self-contained modular manufacturing devices.
  • Another optional step may be loading parameters for accomplishing the manufacturing functions from a local memory disposed in one or more of the self-contained modular manufacturing devices prior to accomplishing any manufacturing function.
  • Yet another option is to have third and fourth functions locally control after a control handshake.
  • step 630 the method ends at step 630 . Additional steps may be added in other embodiments, such as additional control handshakes with nested controllers as well as multiple functions at the same position, such as locating, drilling, measuring and installing a fastener with respect to a hole. Further, the steps of this method need not be performed in exactly the order depicted in FIG. 6 and some steps may be omitted.
  • the above example is just one illustrative example out of many illustrative examples.

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US14/876,564 US10025299B2 (en) 2015-10-06 2015-10-06 System and method for self-contained modular manufacturing device having nested controllers
EP16854075.5A EP3359342B1 (de) 2015-10-06 2016-09-22 System und verfahren für eigenständige modulare herstellungsvorrichtung mit verschachtelten steuergeräten
PCT/US2016/053096 WO2017062187A1 (en) 2015-10-06 2016-09-22 System and method for self-contained modular manufacturing device having nested controllers
PT168540755T PT3359342T (pt) 2015-10-06 2016-09-22 Sistema e método para controladores de fabrico modular autónomos
ES16854075T ES2969438T3 (es) 2015-10-06 2016-09-22 Sistema y método para un dispositivo de fabricación modular autónomo que tiene controladores anidados
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US20180292814A1 (en) 2018-10-11
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PT3359342T (pt) 2024-01-26
US20170097633A1 (en) 2017-04-06
US10429824B2 (en) 2019-10-01
WO2017062187A1 (en) 2017-04-13
EP3359342B1 (de) 2023-11-01

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